Field replaceable buckle with reinstallable cross bar

ABSTRACT

A field replaceable buckle with reinstallable cross bar includes at least one buckle part having a pair of lateral lugs extending therefrom. Each lateral lug has at least one aperture provided therein. The reinstallable cross bar includes a securing portion and a retaining portion. When the reinstallable cross bar is inserted through an aperture in a first lateral lug, it is prevented from passing therethrough by the retaining portion and the securing portion is operable to securely, but releasably, engage an aperture in the second lateral lug.

FIELD OF THE INVENTION

The invention relates to a field replaceable cross bar for buckles. The invention is particularly suited to side release buckles consisting of one male and one female component which are releasably lockable together, and where webbing is looped around a single cross bar provided in the proximate end of at least one of the components.

BACKGROUND

The following discussion of the background to the invention is intended to facilitate an understanding of the present invention. However, it should be appreciated that the discussion is not an acknowledgment or admission that any of the material referred to was published, known or part of the common general knowledge in any jurisdiction as at the priority date of the application.

A side release buckle as described in U.S. Pat. No. 5,794,316 assigned to National Moulding Corp. is an example of a fastening device common to the art. The most common use of this type of buckle is to fasten together two entities by way of webbing or straps. In such a configuration, the buckle typically consists of two components—a female socket part and a male plug part. Furthermore, each of these parts typically consists of two sections:

-   -   an engaging section at a distal end; and     -   an attachment section at a proximal end; and

The engaging section typically incorporates the mating component to allow the two parts to securely connect in a releasable manner. The attachment section generally comprises a slot and cross bar arrangement for attaching the webbing or strap.

In some configurations, the webbing or strap is threaded through a slot to form a loop around a cross bar and then fixed on to itself through stitching or other form of securing mechanism (for example, a rivet). The portion of the webbing or strap that encapsulates the cross bar is hereafter referred to as the capturing loop.

A similar capturing loop is formed in buckles that commonly employ what is known in the art as a ladder lock configuration. Such buckles comprise a single component and is fixedly attached to one entity by means of a capturing loop formed around one cross bar. The buckle is then adjustably attached to a second entity by way of webbing alone. This adjustable attachment is achieved by virtue of the path the webbing takes as it is threaded around one or more other components of the buckle.

There are two problems with these structures. Firstly, during production of side release buckles of the first configuration type, the minimum width of the sewing foot of the sewing machine does not allow the stitching to be executed very close to the captured cross bar. This leaves the capturing loop loose around the cross bar. The freedom of movement resulting from this loose fitting is not desirable in some applications where the webbing must remain proud and resist twisting away from the plane of the webbing.

The second problem with these structures is that these buckles, whether of the first or second configuration described, are typically formed from moulded plastic. This plastic is prone to break with extended use or in the case of accidental impact. When broken, as the cross bar forms an integral part of a mating component, there is no way to fix the buckle connection unless the stitching or other securing mechanism is reversed and the webbing re-threaded about the replacement buckle. This often cannot be achieved in a field situation or without the aid of specialised machines or tools.

This problem is further exacerbated when it is considered that such buckles are extensively used in equipment for outdoor and adventure sports and the whole article can be rendered useless or sub-par if a buckle does not work properly. This can also have serious consequences for the user.

It is therefore an object of the present invention to provide a field replaceable buckle with reinstallable cross bar and thus overcome the aforementioned problems.

SUMMARY

Throughout this document, unless otherwise indicated to the contrary, the terms “comprising”, “consisting of”, and the like, are to be construed as non-exhaustive, or in other words, as meaning “including, but not limited to”.

In accordance with a first aspect of the present invention there is a field replaceable buckle with reinstallable cross bar for a buckle, where the buckle comprises at least one buckle part having a pair of lateral lugs extending therefrom and each lateral lug has at least one aperture provided therein and where the reinstallable cross bar includes a securing portion and a retaining portion, such that when the reinstallable cross bar is inserted through an aperture in a first lateral lug it is prevented from passing therethrough by the retaining portion and the securing portion is operable to securely, but releasably, engage an aperture in the second lateral lug.

Preferably, the aperture in the second lateral lug has a depth and the securing portion has a substantially corresponding length.

The securing portion may take the form of a self tapping threaded end. The self tapping threaded end ideally cuts into side walls of the aperture in the second lateral lug as it is received therein by the application of rotational force.

Alternatively:

-   -   the securing portion is magnetised to a first polarity and the         aperture in the second lateral lug is magnetised to a second         polarity such that the securing portion is retained within the         second lateral lug through magnetic forces.     -   the securing portion takes the form of a notch and the aperture         in the second lateral lug incorporates a spring loaded latch,         the spring loaded latch biased to engage the notch when the         securing portion is received within the second lateral lug     -   the securing portion takes the form of a bolt stud adapted to be         securely received within a nut positioned adjacent the aperture         in the second lateral lug in such a manner as to ensure at least         a portion of the cross bar is securely retained within the         second lateral lug.

The retaining portion may incorporate a depressed slot to facilitate the imparting of rotational force to the securing portion.

Preferably, when received within the apertures, the reinstallable cross bar is sufficiently spaced from the buckle part to allow at least a portion of a capturing loop to be received therethrough.

The reinstallable cross bar may further comprise a shaft portion interposed between the retaining portion and the securing portion, the shaft portion having a smooth surface.

In an alternate configuration, the aperture in the first lateral lug has a matching shape and dimension to the shape and dimension of the retaining portion so as to ensure that the retaining portion is flush with an outer surface of the first lateral lug when received therein.

The reinstallable cross bar may be made from stainless steel.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is an exploded view of a buckle incorporating the present invention.

FIG. 2 is a plan view of the buckle shown in FIG. 1 as installed in capturing loops and as engaged.

DETAILED DESCRIPTION

In accordance with a first embodiment of the invention there is a buckle 1 comprising a male prong part 2 and a female socket part 3. Each of the male prong part 2 and female socket part 3 also incorporates a cross bar 4.

The male prong part 2 and female prong part 3 are moulded from Polyoxymethylene.

The male prong part 2 consists of two lateral prongs 12 and a central spine 13. The lateral prongs 12 have a spring cantilevered stem portion 14 terminating in a bulbous end 15. The bulbous end 15 contains a shoulder with a “U”-shaped engaging surface 16. The “U”-shaped engaging surface 16 locks against a similar “U”-shaped wall surface 17 on a lateral aperture 10 of the female socket part 3. This locking arrangement is primarily a result of the dimensional overlap caused when the male prong part 2 is inserted into the female socket part 3.

The central spine 13 is located between the two lateral prongs 12. Provided within the central spine 13 are longitudinal channels 18. The longitudinal channels 18 are disposed on opposite faces 19 to correspond to central ribs 8 contained inside cavity 6 of the female socket part 3. To elaborate, the central ribs 8 slide inside the longitudinal channels 18 when the male prong part 2 is inserted into the female socket part 3. This ensures a symmetrical engagement in a straight line between the male prong part 2 and female prong part 3.

The female socket part 3 consists of a cavity 6 in the main body 5. The cavity 6 has an engaging opening 7 at its distal end 6 in a well known configuration. The cavity 6 contains two central ribs 8 on opposing inside faces 9. The cavity 6 also has lateral apertures 10, in the form of two secondary openings, on side walls 30.

A pair of lateral lugs 11 are provided in the respective proximal ends 31, 32 of male plug part 2 and female socket part 3. Each pair of lateral lugs 11 are designed to accommodate a buckle pin which acts as a single cross bar 4 for a capturing loop 20 of the webbing 21.

To accommodate the cross bar, one of the lateral lugs 11 a has a through countersunk hole 22 provided therein. The countersunk hole 22 is sized to fit a screw head 23 of the cross bar 4. The other lateral lug 11 b contains an opposing hole 24 sized to enable a self tapping threaded end 25 of the cross bar 4 to cut threads in the walls of the hole and thus allow the cross bar 4 to be securely retained in the lateral lugs 11. When so secured, the cross bar 4 bridges the pair of lateral lugs 11.

The position of the through countersunk hole 22 and the opposing hole 24 in their respective lateral lugs 11 is sufficiently spaced from the operative portions 5, 18 of their respective part 2, 3 so as to create a slot 29 between such operative portions 5, 18 and the cross bar 4 when received therein. Furthermore, the slot 29 must be of sufficient width to allow the webbing 21 to be threaded therethrough and around the cross bar 4 so as to create the capturing loop 20.

Each cross bar 4 comprises a screw head 23, a self tapping threaded end 25 and a shaft part 33. The head part 23 is tapered in a countersunk fashion as would be well known to the person skilled in the art. Furthermore the head part 23 is dimensioned so as to fit through countersunk hole 22. This allows the head part 23 to sit flush and in level with top surface 27 of lateral lug 11 b when the cross bar 4 is properly inserted in through countersunk hole 22.

The screw head 23 also has a cross-shaped depressed slot 28 provided therein to facilitate removal of the cross bar 4 by way of a Philips screw driver.

The self tapping threaded end 25 has a series of threads which are sufficiently sharp enough to cut threads into side walls (not shown) of opposing hole 24. In this preferred embodiment, the threaded end 25 has a length roughly equal to the depth of the opposing hole 24.

The shaft part has a smooth external machine finish to minimise abrasion on the webbing 21.

Each cross bar 4 is made from stainless steel.

This embodiment will now be described and further explained in the context of its intended use.

A first webbing 21 a is obtained and a capturing loop 20 formed therein.

Simultaneously, or thereafter, a second webbing 21 b is obtained and a capturing loop 20 also formed therein.

In both cases, the capturing loop 20 is sized and dimensioned such that there is very little free space provided therein once a cross bar 4 extends therethrough.

With the capturing loops 20 formed, each piece of webbing 21 is positioned such that the axis (A-A) of the capturing loop 20 aligns with the countersunk hole 22 and opposing hole 24 of its respective part 2, 3.

With respect to each part 2, 3, a cross bar 4 is then inserted first through the countersunk hole 22 with the self tapping threaded end 25 leading. Following clearance of the countersunk hole 22, the self tapping threaded end 25 enters the capturing loop 20 in line with axis (A-A). The cross bar 4 then continues to be inserted through the capturing loop 20 until such time as the self tapping threaded end 25 meets opposing hole 24. At this position, a Philips head screwdriver must engage the cross shaped depressed slot 28 to impart rotational force to the cross bar 4.

This rotational force allows the sharpened threads of the self tapping threaded end 25 to cut into the side walls of the opposing hole 24. This continues until all of the threads of the self tapping threaded end 25 are received within the opposing hole 24, leaving the capturing loop 20 encapsulating the smooth surface of the shaft part 33.

With the webbing 21 now appropriately secured to their respective parts 2, 3, a secured, releasable buckle 1 is formed as follows.

As the bulbous ends 15 of each lateral prong 12 slopes towards its distal end 34, when the distal end 34 of the male prong part 2 is inserted into an engaging opening 7 at the distal end 26 of the cavity 6, the bulbous ends 15 engage with the lateral walls 19 of the cavity 6 and cause the lateral prongs 12 to compress and flex towards the central spine 13. This enables the male prong part 2 to be progressively narrowed while being inserted into the cavity 6.

When the male prong part 2 has reached its maximum inserted position within the female socket part 3, the lateral prongs 12 are no longer constrained by the cavity 6. As a result, the accumulated flexing force of the lateral prongs 12 is released, causing them to spring outwards. This movement also sees the bulbous ends 15 snap into lateral apertures 10 located near the proximal end of the female socket part 3.

At this point, the shoulder 16 of the male prong 12 and the wall surface 17 of the lateral aperture 10 overlap dimensionally and thereby create a secure mechanical connection between the male prong part 2 and the female socket part 3.

The buckle 1 may thereafter be released by applying inward pressure to the lateral prongs 12 such that they move towards the central spine 13. As this inward pressure increases, the lateral prongs 12 will reach a point where the bulbous ends 15 can disengage from the lateral apertures 10. When so disengaged, the male prong part 2 can then be removed from the female socket part 3, by applying a separating force to one or both respective webbings 21.

Once disengaged, the cross bar 4 may then be removed by reversing the process described above. This can then allow the buckle 1 to be replaced as required.

It should be readily apparent to the person skilled in the art that the above description illustrates a buckle 1 which can easily be replaced in the field in the event that the buckle is rendered useless due to damage to any of its constituent parts. Similarly, it should be noted by the person skilled in the art that as the cross bar 4 is not an integral component of either part 2, 3 the technical limitations of sewing machines as described above becomes irrelevant. Rather the countersunk hole 22 and opposing hole 24 can be placed anywhere in the lateral lugs 11 provided that this creates a slot 29 of sufficient size to allow a relevant portion of the capturing loop 20 to pass therethrough.

It should also be appreciated by the person skilled in the art that the above invention is not limited to the embodiment described. In particular, the following modifications and improvements may be made without departing from the scope of the present invention:

-   -   The male prong part 2 and female prong part 3 may also be made         of Poly Amide copolymer plastics or resins but any suitable         material known in the art for moulding or machining side release         buckles can be used.     -   Similarly, the cross bars 4 may be made from any material known         in the art for moulding or machining bolts, pins or screws.     -   The buckle 1 may take a form other than the side release buckle         described above. For instance, the buckle 1 may take any other         two-part form used to latch two webbing parts or straps         together. In this respect, the securing mechanism for fixing the         webbing parts or straps together can take any form that         incorporates a bar and capturing loop configuration as would be         known to the person skilled in the art.     -   It should also be noted that in two part buckle configurations,         only one part need employ a cross bar 4. The other part may take         the form of a double slot arrangement in which the webbing 21 is         simply threaded through these slots. This is a common         arrangement in situations where the buckle 1 is not designed to         be captured at a fixed location along the webbing 21.     -   Similarly, the invention may also be employed in single part         buckles employing a ladder lock configuration as described         above.     -   An end of the webbing 21 not attached to one of the parts 2, 3         may be affixed to an article. Alternatively, the respective ends         of the webbing 21 may each terminate in a capturing loop 20 that         affixes to a respective part 2, 3.     -   The screw head 23 may be made in any desired shape.     -   The screw head 23 may have a differing shaped depressed slot 28         provided therein to facilitate removal of the cross bar by way         of other standard or customised screw driving tools.     -   The male prong part 2 and female socket part 3 may be adapted         such that their respective lateral lugs 11 are able to retain         multiple cross bars 4 in the manner described above.     -   The cross bar 4 may omit the self tapping threaded end 25 with         other mechanisms for securing the cross bar 4 within opposing         hole 24. For instance, the cross bar 4 and opposing hole 24 may         be appropriately magnetised to facilitate secure magnetic         retention of the cross bar 4 within the opposing hole 24.     -   Other means of securing the cross bar 4 in the opposing hole 24         include incorporating a spring loaded latch within the buckle,         the latch being operable to engage with a notch provided in the         cross bar 4 when the cross bar is received within the opposing         hole 24. Alternatively, the self-tapping threaded end 25 of the         cross bar 4 may be replaced with a bolt stud incorporating         threaded components, such a cross bar 4 may then be adapted to         be screwed into a nut on one or both sides of the opposing hole         24.     -   While the capturing loop 20 has been described as being made         from webbing, the capturing loop 20 may be formed from an         attachment, or attachments, to the webbing. Such attachments are         many and varied, but all must have the necessary dimensions to         pass through slot 29.     -   Alternatively, the attachment may be directly affixed to an item         without any intermediate webbing, the attachment simply acting         as a capturing loop 20 for the item.

It should be further appreciated by the person skilled in the art that the above variations and modifications, not being mutually exclusive, can be combined to form yet further embodiments that fall within the scope of the present invention. 

We claim:
 1. A field replaceable buckle with reinstallable cross bar, where the buckle comprises at least one buckle part having a pair of lateral lugs extending therefrom and each lateral lug has at least one aperture provided therein and where the reinstallable cross bar includes a securing portion and a retaining portion, such that when the reinstallable cross bar is inserted through an aperture in a first lateral lug it is prevented from passing therethrough by the retaining portion and the securing portion is operable to securely, but releasably, engage an aperture in the second lateral lug.
 2. The field replaceable buckle with reinstallable cross bar according to claim 1, where the aperture in the second lateral lug has a depth and the securing portion has a substantially corresponding length.
 3. The field replaceable buckle with reinstallable cross bar according to claim 1, wherein the securing portion is a self tapping threaded end.
 4. The field replaceable buckle with reinstallable cross bar according to claim 3, wherein the self tapping threaded end cuts into side walls of the aperture in the second lateral lug as it is received therein by the application of rotational force.
 5. The field replaceable buckle with reinstallable cross bar according to claim 1, wherein the securing portion is magnetised to a first polarity and the aperture in the second lateral lug is magnetised to a second polarity such that the securing portion is retained within the second lateral lug through magnetic forces.
 6. The field replaceable buckle with reinstallable cross bar according to claim 1, wherein the securing portion takes the form of a notch and the aperture in the second lateral lug incorporates a spring loaded latch, the spring loaded latch biased to engage the notch when the securing portion is received within the second lateral lug.
 7. The field replaceable buckle with reinstallable cross bar according to claim 1, wherein the securing portion takes the form of a bolt stud adapted to be securely received within a nut positioned adjacent the aperture in the second lateral lug in such a manner as to ensure at least a portion of the cross bar is securely retained within the second lateral lug.
 8. The field replaceable buckle with reinstallable cross bar according to claim 1, wherein the retaining portion incorporates a depressed slot to facilitate the imparting of rotational force to the securing portion.
 9. The field replaceable buckle with reinstallable cross bar according to claim 1, wherein the reinstallable cross bar, when received within the apertures, is sufficiently spaced from the buckle part to allow at least a portion of a capturing loop to be received therethrough.
 10. The field replaceable buckle with reinstallable cross bar according to claim 1, further comprising a shaft portion interposed between the retaining portion and the securing portion, the shaft portion having a smooth surface.
 11. The field replaceable buckle with reinstallable cross bar according to claim 1, wherein the aperture in the first lateral lug has a matching shape and dimension to the shape and dimension of the retaining portion so as to ensure that the retaining portion is flush with an outer surface of the first lateral lug when received therein.
 12. The field replaceable buckle with reinstallable cross bar according to claim 1 wherein the reinstallable cross bar is made from stainless steel. 